Lighting assembly

ABSTRACT

A modular lighting assembly uses LED banks as the light sources. The assembly allows the power supply and LED banks to be independently replaced. The assembly uses a power supply that is separated from the LED banks and electrically connected to the LED banks with a plug connector that may be unplugged and plugged back in to allow the power supply or LED bank to be independently and readily replaced. The assembly provides for easy replacement of the different components of the assembly. One feature that makes the components easier to replace is that the light modules and/or the power supply may be carried by the housing that is removable from the base mount that is secured to a mounting structure such as a wall or ceiling.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application claiming priority to U.S.patent application Ser. No. 13/271,115 filed Oct. 11, 2011, whichapplication claims the benefit of U.S. Provisional Application Ser. No.61/391,608 filed Oct. 9, 2010; the disclosures of both are incorporatedherein by reference.

BACKGROUND OF THE DISCLOSURE

1. Technical Field

The disclosure generally relates to LED lighting devices and, moreparticularly, to modular LED lighting units that may be uniquelyconfigured by the user at the location where the lighting is desired.

2. Background Information

Although the benefits of upgrading traditional lighting to efficientlighting based on light emitting diodes (LEDs) is known, additional LEDlighting configurations are desired in the marketplace.

SUMMARY OF THE DISCLOSURE

The disclosure provides a modular lighting assembly using LED banks asthe light sources. The assembly allows the power supply and LED banks tobe independently replaced. The assembly uses a power supply that isseparated from the LED banks and electrically connected to the LED bankswith a plug connector that may be unplugged and plugged back in to allowthe power supply or LED bank to be independently and readily replaced.

The disclosure provides an assembly that provides for easy replacementof the different components of the assembly. One feature that makes thecomponents easier to replace is that the light modules and/or the powersupply may be carried by the housing that is removable from the basemount that is secured to a mounting structure such as a wall or ceiling.This configuration allows the replacement to occur at ground levelrather than requiring the worker to be positioned up on a ladder.

The disclosure also provides a mount that allows the power supply andLED banks to be placed at different locations and allows for the LEDbanks and power supplies to be removed and replaced.

The mount allows the light generated from the system to be directed indifferent directions based on the installation position of the LEDbanks. The housing that mounts the light modules is angled at differentdirections with respect to its base to cast the light generated by thelight modules in desired directions.

The disclosure also provides a lighting assembly that has a low powermode that may be activated to reduce power consumption. The low powermode may be activated manually, automatically, or remotely.

The disclosure also provides a lighting assembly that may be used inunderground applications including underground train systems.

The disclosure provides a LED lighting assembly that may be powered froma 480V, three phase input.

The disclosure provides a lighting assembly with improved efficiency.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is perspective view of an exemplary modular light assembly.

FIG. 2 is an exploded perspective view of the assembly of FIG. 1.

FIG. 3 is an exploded perspective view showing how the power supply andLED banks interact with the mount.

FIG. 4 is a view similar to FIG. 1 showing an alternative configurationfor the modular light and mount.

Similar numbers refer to similar parts throughout the specification.

DETAILED DESCRIPTION OF THE DISCLOSURE

An exemplary configuration of a lighting assembly is indicated generallyby the numeral 2 in the accompanying drawings. Lighting assembly 2 maybe used in a wide variety of environments and is particularly configuredfor underground utility or underground transportation applications.Assembly 2 may be used for tunnel lighting, subways, parking garages,harsh-environment conditions, architectural and industrial operationsincluding petroleum, mining, and power generation. Assembly 2 isconfigured to function in damp environments and is configured to beimpervious to dust such as steel dust and corrosion. Assembly 2 isconfigured to have an operating temperature in the general range of −20°to 50° C.

Assembly 2 uses a plurality of light emitting diode (LED) light sourcesgrouped to function as a single light source referred to herein as anLED banks or LED light module 4. Module 4 provides the desired lightfrom assembly 2. Assembly 2 allows the individual elements of theassembly to be replaced and reconfigured as desired by the end user.Assembly 2 allows the user to select the type of light module 4 used atdifferent locations. For example, the user may install large and smalllight modules 4, different color light modules 4, light modules 4 havingdifferent shapes, or light modules 4 of differing lumen output. The LEDsare configured with an automotive-grade polycarbonate lens assembly. Theinjection molded components are low smoke, zero halogen (LSZH). Eachmodule 4 includes a die-cast aluminum heat sink. Each module 4 has a LEDDriver operating voltage of 100-277 VAC, 480 VAC. Alternate high-voltageAC/DC input may be provided. The power consumption for one exemplaryconfiguration is 60 Watts. The LEDs may be high-output bright whiteLED's (˜4700K). The LEDs have a rated life of 70% lumen maintenance at50,000 hours. Modules 4 use the proprietary, precision Opticlear™ Engineto maximize light distribution to target area while minimizing glare.

Assembly 2 generally includes at least one LED module 4, a mount 6, anda power supply 10. Mount 6 is configured to carry at least one module 4and a power supply 10. A plurality of identical or different lightmodules 4 may be carried by mount 6. Mount 6 may be provided indifferent configurations to direct the light produced by assembly 2 indifferent directions. Each module 4 and supply 10 may be readily mountedand dismounted to mount 6 and may be connected and disconnected fromeach other to allow each individual element to be replaced as needed.

Power supply 10 transforms the alternating current from commonlyavailable electrical power sources such as 110V or 220V or a highvoltage source such as 480V-three phase, to a low voltage direct currentpower supply that is delivered to module 4 with a supply cord 12. Supplycord 12 (shown disconnected in FIG. 1 and connected in FIG. 4), powersupply 10, and/or module 4 include connectors 14 configured to allowcord 12 to be readily connected and disconnected from supply 10 and/ormodule 4. Connectors 14 may be waterproof and locking. A waterproof IP67connector may be used. As shown in FIG. 4, modules 4 may be connectedtogether with a secondary electrical connector 16 such that theelectrical supply flows through one module 4A to the second module 4B.Alternatively, power supply 10 may include multiple outlets 18 with anindependent supply cord 12 used with each module 4. Power supply 10 mayinclude a plug that allows assembly 2 to be plugged into the availableelectrical source or assembly 2 may be hard wired into the electricalsource. Power supply 10 may be configured to function with a wide rangeof input voltages and may be configured to withstand power spikes. Inthe exemplary configuration, power supply 10 outputs a 24V to eachsupply cord 12. Power supply 10 may be double fused.

Assembly 2 may be provided with a low power feature that may beactivated to reduce the amount of power consumed by assembly 2. In oneconfiguration, the low power mode reduces power consumption by 75percent. The low power mode may be activated and deactivated with abutton or switch on power supply 10. Other configurations allow the lowpower mode to be activated or deactivated remotely through a wirelessconnection, through a computer network connection such as an Internetconnection, and/or through a powerline network. These activation methodsalso may be used to turn assembly 2 on and off. Communication betweenpower supply 10 and the controlling device (which may be a computer or atimer) may be through a computer network such as the Internet or anintranet, through a telephone network, through a wireless communicationchannel, or through any other suitable communication channel.

Mount 6 includes a base 20 and a housing 22. Base 20 is configured to besecured to a structure such as a wall or ceiling while housing 22carries module 4 or modules 4. Modules 4 may be secured to housing 22with connectors, a snap fit connection, or the like. Housing 22 definesan opening for each bank of LEDs in module 4. In other configurations,housing 22 is configured to carry or at least cover power supply 10.Housing 22 is readily removably from base 20 so that module 4, modules4, or supply 10 may be replaced, reconfigured, or serviced. When module4 is to be replaced, module 4 is unplugged from supply 10 and housing 22and module 4 are removed together so that the replacement module 4 maybe inserted into housing 22 in a location separate from the locationwhere base 20 remains mounted.

Housing 22 may be angled up, down, left, right, or parallel with respectto base 20. When housing 22 carries multiple modules 4, housing 22 maybe configured to hold modules 4 at different angles with respect to baseplate 28. In the exemplary configuration, housing 22 is angled down withrespect to base 20 such that the light produced by module 4 or modules 4is angled down. As such, when base 20 is mounted to a vertical surfacesuch as a wall, the light produced by assembly 2 is angled down towardthe floor. Also in the exemplary configuration, the center of housing 22is taller than the ends of housing 22 so that the two different lightmodules 4 carried by housing 22 are angled away from each other.

Housing 22 may define a plurality of openings to allow air to circulatearound module 4, modules 4, and power supply 10.

Base 20 includes a generally flat base plate 28 that defines a pluralityof mounting holes 30 that allow base 20 to be secured to a wide varietyof surfaces with a wide variety of connectors. Each mounting hole isdefined by a portion of plate 28 that projects rearwardly from a planarrear surface portion of plate 28. Base plate 28 has a first end 32, asecond end 34, an upper edge 36, and a lower edge 38. Channels aredefined along upper and lower edges 36 and 38 with lips 40 and 42,respectively.

Flanges 44 projecting from housing 22 are sized to slide within thesechannels between lips 40/42 and base plate 28 to retain housing 22 withrespect to base 20. Power supply 10 includes its own flanges 46 thatproject from a power supply mounting plate 48 that mounts power supply10 to base in the same manner. Flanges 44/46 may be freely slidablewithin the channels or may be tapered to allow for easy insertion andfrictional locking within the channels. The frictional locking occurswhen the tip-to-tip distance from flange 44 to the opposite flange 44 isessentially the same dimension - or just smaller than—the dimension fromthe inside of one channel to the inside of the other channel. FIGS. 2and 3 depict tapered ends on flanges 44 while FIG. 4 depicts roundedends. Flanges 44 also may be frictionally pinched by being slightlythicker than the channels.

Power supply 10 may be connected to base 20 by sliding flanges 46 intothe open end of the channels behinds lips 40/42 at second end 34 of base20. A stop 50 projects forward from base plate 28. Power supply 10 abutsstop 50 when in the proper position. A connector, such as a screw orbolt, may be used to secure power supply 10 in place. Supply cord 12also holds power supply 10 in place. Alternatively, flanges 46 may beconfigured to lock into the channels with friction fits or snap fits. Inother configurations, power supply 10 is mounted within and carried byhousing 22.

Flanges 44 may be continuous such that housing 22 is slid into thechannels through first end 32 in the same manner as power supply 10. Inthe exemplary configuration, flanges 44 are spaced and lip 40 definesgaps 52 so that housing 22 may be installed by resting its lower flange44 behind lip 42 with the upper flanges 44 aligned with gaps 52. Housing22 is then pivoted toward plate 28 until its upper flanges 44 arealigned with the channel behind lip 40. Housing 22 is then slid sidewaysuntil at least a portion of the upper flanges 44 are disposed behind lip40.

There are alternatives to lock housing 22 in place with respect to base20. Flanges 44 may be configured to lock into the channels with snapfitting members. Alternatively, a mechanical connector may be usedbetween housing 22 and base 20.

In one configuration, gaps 52 are configured to allow housing to bepositioned behind lips 40/42 and slid to the right until housing abutsstop flanges 54. In other configurations, flanges 54 pivot out of theway or are configured to not interfere with housing 22 during theinstallation of housing 22.

In the foregoing description, certain terms have been used for brevity,clearness, and understanding. No unnecessary limitations are to beimplied therefrom beyond the requirement of the prior art because suchterms are used for descriptive purposes and are intended to be broadlyconstrued. Moreover, the description and illustrations provided hereinare examples and the invention is not limited to the exact details shownor described. Throughout the description and claims of thisspecification the words “comprise” and “include” as well as variationsof those words, such as “comprises,” “includes,” “comprising,” and“including” are not intended to exclude additives, components, integers,or steps.

1. A lighting assembly, comprising: an elongate base comprising a firstchannel formed along a first elongate base edge of and a second channelformed along a second elongate base edge; an elongate housing having afirst projection formed along a first elongate housing edge and adaptedto be received within the first channel to engage the elongate base; afirst LED module carried by the housing; and a power supply covered bythe elongate base and the elongate housing when the elongate base iscoupled to the elongate housing, wherein the power supply iselectrically coupled to the first LED module.
 2. The lighting assemblyaccording to claim 1, wherein the first projection comprises a flange.3. The lighting assembly according to claim 1, wherein the first LEDmodule has a length substantially equal to a length of the housing. 4.The lighting assembly according to claim 1, wherein the elongate housingincludes a plurality of snap fit connectors adapted to engage the firstLED module.
 5. The lighting assembly according to claim 1, wherein thefirst channel includes a first lip projecting toward the second channeland adapted to engage first projection.
 6. The lighting assemblyaccording to claim 5, wherein, when the first lip is engaged with thefirst projection, the elongate housing is pivotable relative to theelongate base.
 7. The lighting assembly according to claim 5, whereinthe elongate housing comprises a second projection formed along a secondelongate housing edge and adapted to align with the second channel. 8.The lighting assembly according to claim 7, wherein the secondprojection includes a mechanical connector for coupling the elongatehousing to the elongate base.
 9. The lighting assembly according toclaim 8, wherein the mechanical connector releasably locks the elongatehousing to the elongate base.
 10. The lighting assembly according toclaim 1, wherein the power supply is secured to the elongate base. 11.The lighting assembly according to claim 1, wherein the power supply issecured to the elongate housing.
 12. The lighting assembly according toclaim 1, further comprising: a second LED module carried by the housing.13. The lighting assembly according to claim 12, wherein the first LEDmodule is disposed at a first angle relative to the elongate base foremitting light in a first direction, and the second LED module isdisposed at a second angle relative to the elongate base for emittinglight in a second direction, different than the first direction.
 14. Thelighting assembly according to claim 12, wherein the elongate housingincludes a first opening axially aligned with a second opening such thatthe first LED module is disposed over the first opening and the secondLED module is disposed over the second opening.
 15. The lightingassembly according to claim 12, further comprising: a first electricalconnector coupling the power supply to the first LED module and a secondelectrical connector coupling the first LED module to the second LEDmodule.
 16. The lighting assembly according to claim 12, furthercomprising: a first electrical connector coupling the power supply tothe first LED module and a second electrical connector coupling thepower supply to the second LED module.
 17. The lighting assemblyaccording to claim 1, wherein the power supply is adapted to receivepower from at least two power sources.
 18. The lighting assemblyaccording to claim 17, wherein the at the least two power sourcesincludes a first power source and a second power source, wherein thesecond power source is a higher voltage than the first power source. 19.The lighting assembly according to claim 18, wherein the first powersource is at least 110V and the second power source is at least 480V.20. The lighting assembly according to claim 18, wherein the at leasttwo power sources includes a third power source.
 21. A lightingassembly, comprising: an elongate base comprising a first channel formedalong a first elongate base edge, wherein the first channel includes alip; an elongate housing having a first projection formed along a firstelongate housing edge and adapted to be received within the firstchannel, wherein the first projection is pivotably connected to thefirst lip; a first LED module carried by the housing; and a power supplywithin the elongate housing and covered by the elongate base and theelongate housing when the elongate base is coupled to the elongatehousing, wherein the power supply is adapted to receive power from atleast two power sources.
 22. The lighting assembly according to claim21, wherein the at the least two power sources includes a first powersource and a second power source, wherein the second power source is ahigher voltage than the first power source.
 23. The lighting assemblyaccording to claim 22, wherein the first power source is at least 110Vand the second power source is at least 480V.
 24. The lighting assemblyaccording to claim 23, wherein the at least two power sources includes athird power source.
 25. A lighting assembly, comprising: an elongatebase; an elongate housing releasbly coupled to the elongate base; afirst LED module carried by the elongate housing; and a power supplyelectrically coupled to the first LED module, wherein the power supplyis adapted to receive power from a first power source of at least 110Vand a second power source of at least 480V.
 26. The lighting assemblyaccording to claim 25, wherein the power supply is adapted to receivepower from a third power source.